This procedure covers the removal and replacement of the front upper control arm on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Front upper control arm × 1 — Use OEM specification
• Upper ball joint nut × 1 — Replace if damaged or OEM recommendation
• Control arm mounting bolts × 2 — Replace if worn or OEM recommendation

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at manufacturer frame jacking points
5. Remove front wheel on side being serviced
6. Spray control arm bolts and ball joint nut with penetrating oil if corrosion is present

Procedure

1. 1

   Support the knuckle assembly
   Position a floor jack under the lower control arm or knuckle to support the suspension assembly. Raise jack slightly to take tension off the upper control arm but do not lift the vehicle. This prevents the suspension from dropping when the upper ball joint is disconnected.
2. 2

   Remove upper ball joint castle nut
   Remove the cotter pin from the upper ball joint castle nut if equipped. Using a 19mm socket, remove the castle nut from the upper ball joint stud. Keep the nut if reusing, otherwise discard.
   ℹ️Some model years may use a standard nut instead of a castle nut. Verify nut type before removal.
3. 3

   Separate ball joint from knuckle
   Using a ball joint separator or pickle fork, separate the upper ball joint stud from the steering knuckle. Position the tool between the control arm and knuckle, then apply force to break the taper. Once separated, lower the jack slightly to provide clearance for control arm removal.
   ⚠Avoid damaging the ball joint boot if you plan to reuse the control arm. If replacing the control arm, a pickle fork can be used without concern.
4. 4

   Remove rear control arm bolt
   Locate the rear mounting bolt that connects the control arm to the chassis. Using a 17mm socket and wrench, remove the rear mounting bolt completely. This bolt may require significant force to break free. Support the control arm by hand as you remove the bolt.
   ℹ️The rear bolt is typically accessed from the engine bay side. You may need to reach through the wheel well.
5. 5

   Remove front control arm bolt
   Using a 17mm socket and wrench, remove the front mounting bolt that secures the control arm to the chassis. Once removed, carefully lower the control arm and remove it from the vehicle. Note the orientation and position of any washers or shims for reinstallation.
6. 6

   Inspect mounting points and clean surfaces
   Inspect the chassis mounting points for damage, elongation, or corrosion. Clean all mounting surfaces with a wire brush. Check the knuckle ball joint taper bore for damage. If contaminated with grease from a torn boot, clean thoroughly before installing the new control arm.
7. 7

   Install new upper control arm
   Position the new upper control arm into the chassis mounting brackets. Insert both the front and rear mounting bolts finger-tight only. Do not torque at this time. Ensure any alignment shims or washers are in their original positions.
   ⚠Control arm bolts must remain loose until vehicle weight is on the wheels to prevent bushing wind-up and premature failure.
8. 8

   Connect ball joint to knuckle
   Raise the floor jack under the lower control arm to align the upper ball joint stud with the hole in the steering knuckle. Insert the ball joint stud into the knuckle taper. Install the new castle nut onto the ball joint stud and tighten.
   ℹ️If using a castle nut, tighten to specification then advance to the next cotter pin slot if needed. Never loosen to align cotter pin holes.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
9. 9

   Install wheel and lower vehicle
   Reinstall the wheel and hand-tighten all lug nuts in a star pattern. Lower the vehicle until the tires just contact the ground but the suspension is not yet fully loaded. Torque the lug nuts to specification in a star pattern.
   Torque spec

   Wheel Lug Nuts136 Nm (100 lb-ft)
10. 10

    Torque control arm bolts with weight on wheels
    With the vehicle now on the ground and suspension at normal ride height, torque both the front and rear control arm mounting bolts to specification. This ensures the bushings are not pre-loaded in the wrong position. Use a breaker bar and torque wrench, working from under the vehicle.
    ⚠This step is critical. Torquing with suspension hanging will cause bushing failure within a few thousand miles.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Install new cotter pin through castle nut and ball joint stud if equipped
2. Remove floor jack from under vehicle
3. Verify all fasteners are properly torqued
4. Test drive vehicle at low speed to verify no unusual noises

Verification

• Perform a visual inspection to confirm all bolts are installed and torqued
• Check that the ball joint nut is properly secured with cotter pin if applicable
• Test drive and verify no clunking or suspension noise during turns and bumps
• Schedule a front-end alignment as soon as possible, as control arm replacement will affect camber and caster settings

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